Gypsum board forming device with improved slurry spread

ABSTRACT

Disclosed is a gypsum board forming device which provides improved slurry spread. The device includes a forming table with an arcuate or angled profile that promotes a uniform slurry spread. An arcuate or angled hinge plate can also be included to further promote the uniform distribution of slurry prior to an extrusion plate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to applicationSer. No. 11/853,052, filed on Sep. 11, 2007, and issuing as U.S. Pat.No. 8,177,541 on May 15, 2012, which itself claims priority to U.S.Provisional Patent Application Ser. No. 60/844,129, filed Sep. 11, 2006,the disclosures of which are herein incorporated by reference in theirentirety, and all commonly owned.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a system for improving slurry spread. Morespecifically, the present invention relates to a forming table with anarcuate or angled cross section that improves the distribution of slurryin the area immediately prior to the pinch point.

2. Description of the Background Art

The prior art contains several examples of gypsum board forming devices.These devices employ various mechanisms for ensuring the shape andquality of the resulting board. For example, U.S. Pat. No. 2,722,262 toEaton discloses an apparatus for the continuous production of a paperencased gypsum plaster strip. The apparatus includes a table over whicha continuous strip is passed. The apparatus further includes a block andside guide members for shaping the strip and associated gypsum.

Additionally, U.S. Pat. No. 3,373,065 to Gutzman discloses a gypsumboard forming machine. Support guides on the bed of the machine raisethe edge portions of the bottom cover sheet to form a trough. Due to thedepth of the trough, the head of the slurry which accumulates at theentrance to a board forming passageway is laterally confined.

U.S. Pat. No. 1,751,953 to Spengler discloses a plaster boardmanufacturing apparatus. The apparatus includes a conveyor onto which aplastic material is deposited. Damming bars are provided to prevent theplastic material from flowing from the applied sheet or from banking toonear the edge thereof.

Finally, U.S. Pat. No. 5,718,797 to Phillips et. al. discloses anapparatus for manufacturing gypsum board. The apparatus includes aconveyor and a duct for dispensing gypsum slurry. The slurry flows andspreads out across an underlying sheet. Folding shoes are included atthe borders for folding the borders upwardly.

Although the above referenced inventions achieve their individualobjectives, all suffer from common drawbacks. Namely, none of thereferenced inventions is directed at promoting the uniform distributionof slurry adjacent a pinch point.

SUMMARY OF THE INVENTION

It is therefore one of the objectives of this invention to provide agypsum board forming device that promotes the uniform distribution ofslurry adjacent a pinch point. [9] It is yet another objective of thisinvention to provide a gypsum board forming device the promotes thespread of slurry to the edges of an associated forming table.

It is another objective of this invention to provide a gypsum boardforming device that produces boards without voids and that have animproved strength and durability.

The foregoing has outlined rather broadly the more pertinent andimportant features of the present invention in order that the detaileddescription of the invention that follows may be better understood sothat the present contribution to the art can be more fully appreciated.Additional features of the invention will be described hereinafter whichform the subject of the claims of the invention. It should beappreciated by those skilled in the art that the conception and thespecific embodiment disclosed may be readily utilized as a basis formodifying or designing other structures for carrying out the samepurposes of the present invention. It should also be realized by thoseskilled in the art that such equivalent constructions do not depart fromthe spirit and scope of the invention as set forth in the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and objects of the invention,reference should be had to the following detailed description taken inconnection with the accompanying drawings in which:

FIG. 1 is a schematic view of a gypsum board forming device.

FIG. 2 a is a cross sectional view taken along line 2-2 of FIG. 1.

FIG. 2 b is a cross sectional view of an alternative embodiment takenalong line 2-2 of FIG. 1.

FIG. 3 a is a cross sectional view taken along line 3-3 of FIG. 1.

FIG. 3 b is a cross sectional view of an alternative embodiment takenalong line 3-3 of FIG. 1.

FIG. 4 is a cross sectional view taken along line 4-4 of FIG. 1.

FIG. 5 is a plan view taken along line 5-5 of FIG. 1.

FIG. 6 is a plan view of a flat forming table.

Similar reference characters refer to similar parts throughout theseveral views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention relates to a gypsum board forming device whichprovides improved slurry spread. The device includes a forming tablewith an arcuate or angled profile that promotes a uniform distributionof slurry. The shape can be used in conjunction with conventionalagitators that are likewise used to promote slurry spread. An arcuate orangled hinge plate can also be included to further promote the uniformdistribution of slurry prior to an extrusion plate. As a result of theimproved slurry distribution, boards with increased strength anddurability can be created. The various details of the present invention,and the manner in which they interrelate, will be described in greaterdetail hereinafter.

With reference now to FIG. 1, the gypsum board forming device 20 of thepresent invention is depicted. Device 20 preferably includes threeforming tables (22, 24 and 26) arranged in end to end fashion.Nonetheless, those skilled in the art will appreciate that any number ofboard forming tables can be employed in conjunction with the presentinvention. As is known, the tables can include vibrators or agitators 50(note FIG. 5) that promote the uniform distribution of slurry.

A gypsum slurry 42 is supplied to the forming tables from a continuousmixer 28 via one or more boots 60. Mixer 28 accepts the raw materialsused to produce gypsum (i.e. stucco, plaster, gypsum, water and otheradditives) and produces a slurry mixture suitable for use in makinggypsum board. The specific mixer 28 depicted includes three outlets (30,32 and 34), although any number of outlets can be employed dependingupon the nature of the boards being produced. Separate mixing chamberscan be included within mixer 28 for the purpose of providing slurry withvarying consistency at the respective outlets. For example, slurry 42provided to the facing sheets of the board may be more dense than theslurry constituting the core of the board.

With continuing reference to FIG. 1, the lower supply roll 36 of thedevice 20 is illustrated. This lower supply roll 36 spools out a bottomfacing sheet 38 to the upper surface of the first forming table 22. Asis known in the art, this bottom facing sheet 38 can take the form of afiberglass mat or a paper sheet. The composition and size of the sheetcan be varied and will depend upon the intended use of the boards beingproduced.

After the facing sheet 38 is laid out on the forming table 22, slurry 42from mixer 28 is dispensed over top of sheet 38 by way of the firstslurry outlet 30. Thereafter, a roll coater 44 is used to spread thegypsum slurry 42 over bottom facing sheet 38. Roll coater 44 preferablysupplies a sufficient amount of pressure to ensure that the slurrypenetrates the fibers of the mat, or is otherwise coated to the paper,so as to create a permanent bond. The speed of the rollers and theapplied pressure can be adjusted to achieve optimal distribution andpenetration. As is known in the art, a tensioning roller can bepositioned immediately below the roller coater 44.

FIG. 1 illustrates that additional slurry 42 is dispensed over thefacing sheet 38 along a second forming table 24 and via the secondslurry outlet 32. This additional slurry 42 forms the core of theresulting gypsum board product. Thus, the amount of slurry supplied bythe second slurry outlet 32 will depend upon the intended use of thegypsum board being created.

A top facing sheet 46 is thereafter supplied from an upper supply roll48. As noted in FIG. 1, additional slurry from outlet 34 can be suppliedto the lower surface of this top facing sheet 46. The slurry supplied tothis facing sheet is preferably more dense than the slurry used to formthe core. Sheet 46 can consist of the same construction used for thelower facing sheet 38. In a manner known in the art, the upper sheet 46is thereafter delivered overtop of the gypsum slurry 42 to form acomposite board construction.

As illustrated in FIG. 1, this upper sheet 46 is preferably delivered tothe process via an extruder assembly. The extruder assembly includesboth a hinge plate 52 and an extruder plate 54. These plates (52 and 54)are pivotally interconnected to one another along a hinge 56 and aregenerally oriented at a distance above the bottom plate of the extruderassembly.

Hinge 56 allows the two plates (52 and 54) to pivot with respect to eachother. In normal operation, slurry accumulates in a head 58 adjacent tothe hinge plate 52. Slurry head 58, in turn, causes the hinge plate 52to pivot upwardly relative to the horizontal. By contrast, once slurry42 reaches the extruder plate 54 it is generally smoothed out and hasattained a thickness that generally matches the desired board thickness.Accordingly, as the hinge plate 52 forces the slurry head 58 intoextruder plate 54, a pinch point 62 is created.

Pinch point 62 may have the undesirable tendency of creating anon-uniform profile in the slurry 42 as it approaches the extruder plate54. This non-uniform profile 64 is illustrated in FIG. 6. Onecharacteristic of this profile is that eddie currents 66 are formed inthe areas adjacent the edges of the forming table 26. The non-uniformslurry 64 distribution has many undesirable consequences. For instance,the resulting gypsum board often includes voids and density variationsthat yield boards of reduced strength.

In accordance with the present invention, a uniform distribution ofslurry is promoted by providing an arcuate cross section 68 along thesecond and third forming tables (24 and 26). More specifically, as notedin FIG. 2 a, table 24 includes a raised central area 72 and lower sideregions 74 in the area immediately adjacent the second outlet 32 ofmixer 28. The profile transitions from the arcuate profile along thesecond forming table 24 (note FIG. 2 a), to a slightly less arcuateprofile along the third forming table 26 (note FIG. 3 a), and finally toa planar profile 78 immediately adjacent the extruder plate 54 (noteFIG. 4). This continuous transition ensures an adequate distribution ofslurry at the slurry head 58, but at the same time ensures that a flatboard is produced within extruder plate 54.

Although the preferred embodiment is described in conjunction witharcuate profiles (note FIGS. 2 a and 3 a), the present invention canalso be carried out with other shapes. For example, forming tables withan angled profile (note FIGS. 2 b and 3 b) and likewise be used topromote slurry distribution. Namely, the tables would include a raisedcenter portion 88 with downwardly sloped sides 86. The preferredembodiment would likewise be tapered from the second to the third tables(24 and 26). In other words, the angle formed along the second table 24(FIG. 2 b) would be greater than angle along the third table 26 (FIG. 3b). This transition would be continuous with a planer cross section 78being achieved immediately before the extruder plate 54 (FIG. 4).

Still yet further slurry distribution can be achieved via an arcuate orangled hinge plate 52. Namely, the distal end 52 a of hinge plate 52 canbe curved upwardly 82 with respect to the third forming table 26 (noteFIG. 3 a). Namely, the curvature 82 of the distal end 52 a of plate 52would be opposite the curvature 68 of the underlying table 26. As notedin FIG. 3 a, this has the tendency of forcing the slurry 42 betweenplate 52 and table 26 to the outer edges of the table, thereby promotinga more uniform distribution. This construction, in turn, eliminates theeddies 66 that would otherwise form between two planar profiles.

Although extruder plate 52 has been described with an arcuate crosssection 82, an angled cross section 92 can also be used at the distalend 52 a of hinge plate 52 (note FIG. 3 b). Again, the preferred angleis opposite the angle of the underlying table 26. In other words,whereas the sides 86 of table 26 are angled downwardly, the sides 90 ofthe distal end 52 a of hinge plate 52 are upwardly angled. Consequently,slurry 42 is pushed outwardly in a manner akin to water passing over aship's bow.

Whatever shape is used for the distal end 52 a of hinge plate 52, theproximal end 52 b adjacent pinch point 62 is planar 80 (note FIG. 4).Again, there is preferably a uniform transition between the distal andproximal ends (52 a and 52 b). This planar cross section 80 of theproximal end 52 b is illustrated in FIG. 4 an ensures that the top sheet46 is evenly applied to the underlying slurry 42.

In still yet further embodiments of the present invention, the shape ofthe distal end 52 a of hinge plate 52 can be changed. In one embodiment,this is achieve by forming hinge plate 52 from an expansible bladderthan can be inflated or deflated as necessary to change the shape and/orcurvature of the plate. In still yet another embodiment, the angledhinge plate 92 includes a hinge intermediate sides 90 which allows theangle formed to be adjusted as needed.

The present disclosure includes that contained in the appended claims,as well as that of the foregoing description. Although this inventionhas been described in its preferred form with a certain degree ofparticularity, it is understood that the present disclosure of thepreferred form has been made only by way of example and that numerouschanges in the details of construction and the combination andarrangement of parts may be resorted to without departing from thespirit and scope of the invention.

What is claimed is:
 1. A gypsum board forming device for facilitatingslurry spread prior to a pinch point, the device comprising: a gypsumslurry mixing device including first and second slurry outlets; a firstforming table having an upper surface; a lower supply roll supplying abottom facing sheet to the upper surface of the first forming table, thefirst slurry outlet supplying slurry over the bottom facing sheet; aroll coater positioned along the first forming table and configured tospread the gypsum slurry over the bottom facing sheet; a second formingtable having a first arcuate cross section, the first arcuate crosssection defined by a raised central area and lower side edges, thesecond slurry outlet supplying additional slurry to the bottom facingsheet along the second forming table, the first arcuate cross sectionconfigured to promote a uniform distribution of the slurry to the lowerside edges of the second forming table; a third forming table having asecond arcuate cross section defined by a raised central area and lowerside edges, the first arcuate cross section being greater than thesecond arcuate cross section.
 2. The gypsum board forming device asdescribed in claim 1, further comprising: a hinge plate secured over thethird forming table, the hinge plate have a proximal end, a distal end,and a longitudinal axis.
 3. The gypsum board forming device as describedin claim 2 wherein the distal end of the hinge plate has a third arcuatecross section, the third arcuate cross section being opposite to thesecond arcuate cross section, the hinge plate being positioned at anangle relative to the third forming table, the third arcuate crosssection configured to create a slurry head, wherein the second arcuatecross section of the third forming table and the third arcuate crosssection facilitate the uniform distribution of the slurry.
 4. A boardforming device to facilitate slurry spread comprising: a supply ofslurry with an outlet; a forming table with opposing sides, alongitudinal axis, and a downstream extent, the forming table beingcrowned about the longitudinal axis, the outlet supplying the slurry tothe forming table at a location adjacent to the longitudinal axis, thecrown configured to promote a uniform distribution of the slurry to theopposing sides of the forming table; a hinge plate positioned along theforming table at a location downstream of the outlet, the hinge plateproducing a slurry head.
 5. The board forming device as described inclaim 4 wherein the hinge plate has a proximal end, a distal end, and alongitudinal axis, the distal end of the hinge plate being curved aboutthe longitudinal axis, wherein a curvature of the hinge plate isopposite to the crown of the forming table, wherein the crown of thetable and the curvature of the hinge plate configured to promote theuniform distribution of the slurry.
 6. The board forming device asdescribed in claim 4 wherein the crown of the table gradually decreasesfrom a location adjacent to the slurry outlet to a location adjacent thehinge plate.
 7. The board forming device as described in claim 5 whereinthe curvature of the hinge plate decreases from the distal to theproximal end.
 8. A board forming device to facilitate slurry spreadcomprising: a supply of slurry with an outlet; a forming table with alongitudinal axis, the forming table having a raised angled profile andlower side edges, the outlet supplying slurry to the forming table, theangled profile configured to promote a uniform distribution of theslurry to the lower side edges of the forming table; a hinge plate andan extruder plate pivotally interconnected to one another, the hingeplate and the extruder plate each having a proximal end, a distal end,and a longitudinal axis.
 9. The board forming device as described inclaim 8 wherein the distal end of the hinge plate is angled about thelongitudinal axis, wherein the angled profiles of the table and hingeplate configured to promote a distribution of the slurry prior to theextruder plate.
 10. The board forming device as described in claim 8wherein an angled profile of the table gradually decreases from alocation adjacent the slurry outlet to a location adjacent the hingeplate.